Method and apparatus for business forms processing

ABSTRACT

A system for stacking continuous folded forms coming from a folder and moving to a conveyor. A table is position adjacent and in line with the conveyor and in a position for receiving a horizontal stack of folded forms disposed on the table top. The table is a tiltable table and is able to be tilted from a substantially horizontal position to a substantially vertical position to likewise move the stack from a horizontal to a vertical stack position. A cart is movable to a position adjacent to the tilted table for receiving from the table the vertical stack for support on the cart.

This application is a division of application Ser. No. 07/832,097, filed on Feb. 6, 1992, now U.S. Pat. No. 5,273,516, issuing Dec. 28, 1993.

BACKGROUND OF THE INVENTION

The present invention relates in general to a method and apparatus for the processing of business forms. More particularly, the present invention relates to a system for stacking continuous folded forms. Even more particularly, the present invention relates to a unique combination of elements used in such a system employing a tiltable table in combination with a stack cart or stack rack.

There are various ways of processing folded forms particularly between an initial folding operation and subsequent finish operations. However, existing transfer systems tend to be rather complex in construction and have rather limited capacity.

It is an object of the present invention to provide a forms transfer system that has an improved capacity and in particular in which a stack rack is used having a capacity of 50,000 forms or more.

Another object of the present invention is to provide an improved system for stacking continuous folded forms in which there is far less frequent intervention by an operator. In accordance with the present invention there is a minimizing of handling of the forms thus minimizing maintenance problems associated with the system.

Still another object of the present invention is to provide a cart system in which the cart is far more space efficient than prior carts. In accordance with the present invention for a particular square footage of coverage of the cart there is a forms capacity far in excess of that previously obtainable.

Another object of the present invention is to provide an improved system for stacking continuous folded forms and associated improved stack rack or stack cart that is relatively inexpensive, of relatively simple construction and one requiring minimal maintenance.

Still another object of the present invention is to provide an improved storage cart for folded forms and one in which it is readily adapted for use with utilization equipment such as feed inserting equipment.

SUMMARY OF THE INVENTION

To accomplish the foregoing and other objects, features, and advantages of the invention there is provided in accordance with the present invention a system for stacking continuous folded forms. The system of the present invention is characterized by simplicity, versatility, flexibility, cost, cost effectiveness, and space efficiency. The system employs a unique combination of elements that enables folded forms to be conveyed, accepted on a tiltable table and then readily transferred to a stack rack or stack cart.

In accordance with the present invention the system may be considered as comprising a folder for folding the forms along fold lines, a conveyor and means for positioning the conveyor adjacent the folder so that the folded forms from the folder are received on and moved along the conveyor. A table is provided having a table top support surface. The table is positioned adjacent and in line with the conveyor and in a position for receiving a horizontal stack of folded forms that are moved by the conveyor and positioned on the table top support surface. In accordance with the embodiment disclosed herein, a flap may bridge between the conveyor and the table which flap is maintained flush with the top surfaces of the conveyor and the table so that the forms pass readily from the conveyor onto the table.

The system of the present invention also provides means for enabling tilting of the table from a substantially horizontal position to a substantially vertical position to in turn move the stack from a horizontally disposed stack to a vertically disposed stack. In the embodiment disclosed herein, associated with the table is a end wall at the end of the table remote from the conveyor and a sliding door at the end of the table adjacent to the conveyor. The sliding door, when the table is in a horizontal position may be disposed depending downwardly but may be moved to an upward position to in essence form an opposite end wall for retaining a stack of folded forms on the table between these end walls. The sliding doors, once the stack is moved to a vertical position functions as resting surface for the stack.

Moreover, in accordance with the system of the present invention there is provided a stack rack or a stack cart. This is movable such as by means of wheels or casters on it and is compartmentalized so as to receive preferably a plurality of these vertical stacks. For this purpose the stack cart is movable to a position adjacent the tilted table, once tilted, for receiving from the table the vertical stack for support on the cart.

In the embodiment of the invention disclosed herein, the cart has a bottom resting surface and vertically disposed walls preferably defining four separate compartments for accommodating vertical stacks. Each of these compartments may also be provided with one or more shelves so as to accommodate stacks of different height. As also indicated previously, the cart is readily rotatable so that once one stack has been loaded the cart can be easily rotated to receive a further stack from the table once the table receives the stack and is tilted.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating a portion of the system of the present invention illustrating a new run coming out of the folder and moving forward on the conveyor as well as a run that is almost totally disposed on the table;

FIG. 2 is perspective view similar to that shown in FIG. 1 but now illustrating a next step in which the sliding door is moved in,to position for retaining the stack on the table;

FIG. 3 is a perspective view showing the flap on the conveyor flipped up and with the table being partially tilted;

FIG. 4 is a perspective showing the table now completely tilted to a vertical position;

FIG. 5 is a perspective view illustrating the table substantially in the position of FIG. 4 but with the door withdrawn as illustrated after the stack cart has been moved into position;

FIG. 6 is a perspective view illustrating the table being moved back to it horizontal position with the flap engaged between the conveyor and the table and with a new group of forms now being conveyed onto the table;

FIG. 7 is a cross sectional view taken along line 7--7 of FIG. 5;

FIG. 8 is a top plan view showing the rack pulled out an rotated with another empty bay ready for the next run which is passing over the flap and about to pass over the end of the sliding door which is now flush with the surface of the tilt table.

DETAILED DESCRIPTION

The drawings in this application illustrate a preferred embodiment for a novel system for stacking continuous folded forms. The system basically employs at least two main elements, one being a table that is adapted to receive forms from a conveyor, and which table is tiltable; and a stack rack or stack cart that is adapted to receive preferably multiple stacks from the table.

FIGS. 1-7 herein are perspective views that illustrate the sequences of events that occur in connection with the use of the apparatus and method of the present invention. Generally speaking, FIG. 1 shows a finished run that is almost completely disposed on the tilt table and a new run coming out of the folder and moving forward on the conveyor. The run that is on the table has just passed off of the conveyor and will then stop moving.

FIG. 2 shows the run shoved over enough to allow the sliding door to come up against the last sheet. This sliding door operation can be carried out manually or some type of automatic system could be employed.

FIGS. 2-5 show the new run slowly progressing out of the folder. FIG. 3 shows the stack partially tilted while FIG. 4 shows the stack in its fully tilted vertical position. FIG. 5 shows the cart engaging with the stack and FIG. 6 shows the cart after having received the stack being moved away so that it can be rotated such as is illustrated in FIG. 8.

With more particular reference to the structure illustrated in the drawings, there is provided a folder 10 that folds the forms into the folded form illustrated in the drawings. The folded forms are shown at 12.

Associated with the folder 10 is a conveyor 16 which may have fixed side walls 18 and a conveying belt 20. The conveyor 16 conveys the forms 12 therealong. In FIG. 1 there is actually illustrated a first stack 12A that has already progressed to the tilt table 24 and a stack 12B that is still progressing along the conveyor 16.

The tilt table 24 has a table top support surface 26 and in the embodiment illustrated herein is comprised of only a single leg 28 although the table could be supported by more than one leg. As illustrated in FIGS. 3 and 4 there is a support bracket 30 that has leg 28 as one member and a further support leg 32 that may fasten to a side of the conveyor 16.

As has been indicated previously, the table 24 is a tiltable table and for this purpose there is provided at the bottom of the table flat surface a pivot mechanism 36 illustrated perhaps best in FIG. 4. This pivot mechanism is supported from the leg 32 of the bracket 30.

Associated with the table are stops. There is a stop 38 illustrated in FIG. 4 that controls the vertical position of the table. There is also a stop 40 illustrated in FIG. 4 that controls the horizontal position of the table 24.

At an end of the table surface 26 remote from the conveyor there is provided an upright end wall 44. This may be permanently fixed in position and simply prevents the stack from falling off that end of the table. The tilt table may also have side walls extending the longitudinal length thereof. Such side walls are not illustrated in the drawings herein.

At the end of the table surface 26 close to the conveyor 16 there is provided a sliding door 46. The door 46 may have detent positions associated therewith so that it can be slid but held in alternate positions. In this regard, in FIG. 1 the door 46 is shown depending downwardly so that the top surface thereof, such as illustrated in FIG. 8, is essentially flush with the table surface 26. In this way, the sliding door is not at all interfering with the progress of the stack 12A as it is moved from the conveyor onto the tilt table. FIG. 2 on the other hand shows the door 46 moved to its upper position whereby detent means or the like it can be retained in that position.

FIGS. 1 and 2 also illustrate a flap 50 that is adapted to bridge between the conveyor 16 and the table 24. The flap 50 is pivotal between a position such as that illustrated in FIG. 2 and that illustrated in FIG. 3. In the position of FIG. 2 the flap 50 has its top surface flush with the top of the conveyor surface namely surface 20 and the top of the table or surface 26. In this way, forms that progress along the conveyor are not at all impeded by the flap but simply pass over the flap.

The flap 50 may also be moved to an upright position as illustrated in FIGS. 3 and 4. In its uprights position the flap 50 may prevent the forms on the conveyor 16 from progressing any further than the position of the flap.

In FIG. 1 the stack 12A has progressed to a point where the conveyor is no longer moving it. The rear end of the stack overlies the flap 50. The sliding door 46 is in its downward position. The front end of the stack may be against the wall 44 or spaced from it as illustrated in FIG. 1.

After the position of FIG. 1, in FIG. 2 the operator may move the stack 12A to the left as illustrated by the arrow and the door 46 is then moved upwardly as also illustrated by the arrow. The door 46 now functions as an opposite end wall so to speak and when the table 24 is tilted it will be seen that the door 46 functions as a base rest surface for the stack 12A. In FIG. 2 the flap 50 is still in its horizontal position.

FIG. 3 now illustrates the flap 50 moved upwardly so as to prevent any further forms from progressing off of the conveyor. Also, in FIG. 3 the table 24 is shown being partially tilted. In FIG. 4 the table has been tilted to its full vertical position whereby the associated stack 12 supported on the table is also in a vertical stack. Note in both FIGS. 3 and 4 that the door 46 is in a position where it functions as a resting surface for the bottom of the stack. In FIGS. 3 and 4 the flap 50 is also maintained in its upright vertical position.

With regard to FIGS. 3 and 4 it is noted that the table 24 is illustrated as being rotated clockwise. Similarly, the table can be rotated counterclockwise. In other words, the table can pivot in either direction. If the table is pivoted in a counterclockwise direction then the endwall 44 functions as a rest surface for the bottom of the stack.

FIG. 5 illustrates the tilt table 24 in the same position as in FIG. 4. The stack 12 is shown in dotted outline. However, FIG. 5 also illustrates the stack rack or stack cart 56 of the present invention. The cart 56 has a base 58 that is supported by four rollers or casters 60. Supported from the base 58 are crossed walls 62 and 64 which define four separate vertically disposed compartment as clearly illustrated in FIGS. 5 and 6. These compartments are also illustrated in FIGS. 7 and 8 such as the compartment 65 that receives the stack 12.

The walls 62 and 64 may be tapered slightly such as illustrated in FIGS. 5 and 6 or they may be straight vertical walls extending from the base. The base 58 in each compartment is preferably tilted such as from a front edge 58A slightly downwardly to a more rear edge 58B (see FIG. 6). This tilting of the base of the cart toward the center assists in holding the stacks in a more stable position on the rack.

FIG. 5 illustrates the cart 56 having been moved into position. The base 58 of the cart is positioned essentially under the sliding door 46 so that there is no interference between the cart and the table 24. It is noted in FIG. 5 that for example, the wall 62 of the cart engages the side of the table as the table is in its vertical position. The door 46 is then slid in the direction of the arrow so as to disengage from the bottom of the stack 12. The stack 12 is then resting upon the base 58 of the cart 56.

The cart 56 may then be moved away from the table such as to the position of FIG. 6. FIG. 6 also illustrates the table being moved in the direction of the arrow in FIG. 6 so that the table is now again in a horizontal position and is ready for the receipt of a further stack. Note in FIG. 6 that the flap 50 is moved downwardly so that the conveyor can now operate to move the next stack onto the table 24.

Thus, in FIG. 6 the cart is shown with only a single stack on it and in a position moved away from the tilt table. FIG. 7 is a cross sectional view taken along line 7--7 of FIG. 5 and thus illustrates the position in a plan view of the cart relative to the tilted table. FIG. 8 illustrates the cart 56 now rotated in the direction of the arrow so that a new compartment 69 may be moved into position to receive a subsequent stack off of the tilt table.

Reference is also now made to an alternate embodiment of the stack rack of the present invention. Once again, this rack is usable to move fan folded or cut-sheet stacks easily and conveniently to the next stop in the output handling sequence. In the alternate embodiment, there are twelve removable shelves as well as four fixed base shelves. These removable shelves in particular allow varying height stacks to be accommodated on the cart.

The cart in accordance with the present invention has a substantially large capacity. It can stock as much as five hours or more of production or, for example, up to 100,000 16-pound 18.5×12 inch pages. This cart occupies in one embodiment approximately only 6.9 square feet. In addition to the casters 60 that are employed it also preferably has at least one handle. All of the shelves that are employed are preferably slanted inwardly so as to keep the stacks square. The cart is made of solid, rugged construction. It is preferably made of a heavy gauge welded steel. The walls are preferably tapered so as to again provide for more stability in holding the stacks of folded or cut-sheet material.

In the foregoing description, reference has been made primarily to the use of the present invention as it pertains to business forms and in particular folded forms. However, the concepts of the present invention may also be employed in connection with the processing of cut sheets.

Having now described a limited number of embodiments of the present invention, numerous other embodiments and modifications thereof are contemplated as falling within the scope of the present invention as defined by the appended claims. 

What is claimed is:
 1. A method for processing continuous folded material comprising the steps of:after folding the material, conveying the material to a table, retaining the material in a stack on the table, moving a retractable barrier, located at an end of the table, into a deployed position, tilting the table to a substantially vertical position and supporting the stack on the barrier, and moving a cart into position at least, in part, under the stack so as to enable transfer of the stack onto the cart.
 2. A method as set forth in claim 1 wherein the step of supporting providing a door and, after the cart is positioned under the stack, moving the door so as to permit the stack to be supported on a base of the cart.
 3. A method as set forth in claim 1 including providing a cart with multiple compartments and rotating the cart so that different compartments can receive different vertically disposed stacks provided in sequence from the table.
 4. A method for processing web material comprising the steps of:conveying the web material in a downstream direction on a conveying surface onto a table including passing the web material over an end of the table and past a predetermined location adjacent the end; retaining the web material in a stack on the table at a location downstream of the predetermined location; positioning a backing surface that extends substantially transversely to a surface defined by the table at the predetermined location; rotating the table about an axis so that the stack of material is supported by the backing surface while the backing surface is located at the predetermined location; and transferring the stack of web material from the table to an adjacent supporting surface.
 5. The method as set forth in claim 4 wherein the step of positioning includes passing the backing surface through a slot in the table so that it is selectively positioned in and out of interfering contact with a path of travel of the web material onto the table.
 6. The method as set forth in claim 5 wherein the step of passing includes sliding the backing surface from a position disposed below the table to a position wherein the backing surface extends above the table.
 7. The method as set forth in claim 4 wherein the step of transferring includes locating the backing surface out of supporting engagement with the stack of web material while the stack of web material is positioned with respect to the the adjacent supporting surface.
 8. The method as set forth in claim 7 further comprising providing wheels to the adjacent supporting surface so that the adjacent supporting surface is portable and moving the adjacent supporting surface at predetermined times with respect to the table.
 9. The method as set forth in claim 7 wherein the step of transferring further comprises locating the backing surface so that the backing surface substantially overlies the adjacent supporting surface to transfer the stack of web material from the backing surface onto the adjacent supporting surface.
 10. The method as set forth in claim 9 further comprising moving the adjacent supporting surface to a position remote from the table subsequent to the step of transferring.
 11. The method as set forth in claim 4 further comprising providing wheels to the adjacent supporting surface so that the adjacent supporting surface is portable and moving the adjacent supporting surface at predetermined times with respect to the table.
 12. The method as set forth in claim 4 wherein the step of transferring includes transferring the stack of material onto a supporting surface that includes a plurality of separated portions thereon and moving the supporting surface to locate one of the plurality of separated portions to receive the stack of web material.
 13. A method for processing folded material comprising the steps of:directing the folded material along a path of travel from a conveyor onto a table and forming a stack of the folded material on the table, the table being disposed in a substantially horizontal orientation to receive the folded material wherein the folded material directed onto the table has an upstream end and a downstream end and wherein the downstream end is located more remote from the conveyor than the upstream end; selectively locating a backing support, subsequent to the step of directing, so that the backing support is in a position, upstream of the upstream end of the stack, that extends into the path of travel of the folded material from a position in which the backing support enables free passage of the folded material along the path of travel onto the table from the conveyor; rotating the table from the substantially horizontal orientation to an orientation that is substantially transverse to the substantially horizontal orientation and supporting the upstream end of the stack on the backing surface in the orientation that is substantially transverse to the substantially horizontal orientation; and transferring the stack from the table onto an adjacent supporting surface including moving the backing surface out of supporting engagement with the upstream end of the stack so that the upstream end of the stack is thereby supported by the adjacent supporting surface.
 14. The method as set forth in claim 13 wherein the step of positioning includes passing the backing surface through a slot in the table so that it is selectively positioned in and out of interfering contact with a path of travel of the web material onto the table.
 15. The method as set forth in claim 13 wherein the step of passing includes sliding the backing surface from a position disposed below the table to a position wherein the backing surface extends above the table.
 16. The method as set forth in claim 13 wherein the step of transferring includes locating the backing surface out of contact with the stack of web material while the stack of web material is positioned with respect to the adjacent supporting surface.
 17. The method as set forth in claim 16 further comprising providing wheels to the adjacent supporting surface so that the adjacent supporting surface is portable and moving the adjacent supporting surface at predetermined times with respect to the table.
 18. The method as set forth in claim 13 further comprising providing wheels to the adjacent supporting surface so that the adjacent supporting surface is portable and moving the adjacent supporting surface at predetermined times with respect to the table.
 19. The method as set forth in claim 13 wherein the step of transferring includes transferring the stack of material onto a supporting surface that includes a plurality of separated portions thereon and moving the supporting surface to locate one of the plurality of separated portions to receive the stack of web material.
 20. A method for processing web material comprising the steps of:folding the web material; conveying the web material onto a table that defines a table surface for receiving and supporting the web material wherein the folded web material progressively defines a stack on the table surface, the stack having a first end and a second end and extending generally in a substantially horizontal direction; positioning a backing surface to define an extended position on the table surface wherein the backing surface extends substantially transverse to the stable surface at a location on the table surface adjacent one of the first end and the second end of the stack of web material the step of positioning including moving the backing surface to the extended position on the table surface from a position wherein the backing surface is unextended relative to the table surface; rotating the table so that the stack of web material is supported on one of the first end and the second end thereof by the backing surface in the extended position and is positioned so that the stack of web material extends substantially in a vertical direction; and transferring the stack of web material from the table to an adjacent supporting surface.
 21. A method as set forth in claim 20 wherein the step of rotating the table causes the stack of web material to move by gravity against the backing surface to be supported thereby.
 22. A method for processing web material comprising the steps of:conveying the web material onto a table having a table surface; forming, on the table surface, a stack of the web material extending in an approximately horizontal direction therealong; providing a first backing surface adjacent an end of the table that extends substantially transversely to the table surface; rotating the table about an axis so that the stack of web material extends in an approximately vertical orientation including supporting the stack of web material on the first backing surface; providing an adjacent supporting surface that receives the stack of web material and that defines a separate surface the table so that the table and the supporting surface are positionable remote from each other; and transferring the stack of web material from the first backing surface onto the adjacent supporting surface so that the stack of web material is supported by the adjacent supporting surface including positioning the adjacent supporting surface relative to the stack of web material so that the stack of web material substantially overlies the adjacent supporting surface and moving the first backing surface to thereby transfer the stack of web material from an overlying position to supported by the adjacent supporting surface.
 23. A method as set forth in claim 22 wherein the approximately horizontal orientation is aligned transverse to a direction of a force gravity and wherein the approximately vertical orientation is approximately aligned with the direction of the force of gravity.
 24. The method as set forth in claim 22 wherein the step of providing the first backing surface includes locating the first backing surface through a slot in the table surface adjacent an upstream end of the table.
 25. The method as set forth in claim 24 wherein the step of locating includes sliding the first backing surface from a position below the table surface out of interfering contact with a path of travel of the web material onto the table to a position in which the backing surface extends into the path of travel.
 26. The method as set forth in claim 22 wherein the step of transferring includes moving the first backing surface through a slot in the table surface so that the backing surface is out of contact with the bottom of the stack of web material.
 27. The method as set forth in claim 22 further comprising providing a second backing surface for supporting an end of the stack adjacent an opposite end of the table relative to the first backing surface,
 28. The method as set forth in claim 22 further comprising moving the adjacent supporting surface to a position remote from the table, subsequent to the step of transferring.
 29. The method as set forth in claim 22 wherein the step of conveying includes conveying the web material in a downstream direction and wherein the table includes an upstream end and a downstream end, wherein the step of providing the first backing surface includes locating the first backing surface adjacent the upstream end.
 30. The method as set forth in claim 22 wherein the step of providing the first backing surface includes moving the first backing surface from a location remote from the table surface into a slot in the table surface into a position that extends substantially transversely to the table surface.
 31. The method as set forth in claim 30 wherein the step of moving the first backing surface includes moving the first backing surface through the slot from a location below the table surface.
 32. The method as set forth in claim 22 wherein the step of providing an adjacent supporting surface includes providing a plurality of locations on the supporting surface for receiving a plurality of stacks of web material from the table.
 33. The method as set forth in claim 22 further comprising providing a second backing surface adjacent an end of the table opposite the first backing surface, the second backing surface extending transversely to the table surface and thereby interfering with passage of web material.
 34. A method for processing web material comprising the steps of:conveying web material from a conveyor onto a table having an upstream end and a downstream end along a path of travel to form a stack of web material having a first end and a second end on the table at a first time; completing a formation of the stack of web material on the table and locating a backing support that extends into the path of travel adjacent the upstream end of the table at a second time; rotating the table so that the first end and the second end define an axis extending therebetween that is approximately aligned with gravity and wherein one of the first end and the second end is supported substantially by the backing support at a third time; and transferring the stack from the backing support onto an adjacent supporting surface and locating the table and the adjacent supporting surface remote from each other subsequent to the step of transferring at a fourth time.
 35. A method for processing web material comprising the steps of:conveying web material from a conveyor onto a table along a path of travel to form a stack of web material having a first end and a second end on the table at a first time; completing a formation of the stack of web material on the table and locating a backing support that extends into the path of travel with respect to one of the first end and the second end at a second time, wherein the step of locating includes moving the backing support from a location remote from a surface of the table into a slot in the table so that the backing support extends substantially transversely to the surface of the table; rotating the table so that the first end and the second end define an axis extending therebetween that is approximately aligned with gravity and wherein one of the first end and the second end is supported substantially by the backing support at a third time; and transferring the stack from the backing support onto an adjacent supporting surface and locating the table and the adjacent supporting surface remote from each other subsequent to the step of transferring at a fourth time.
 36. The method as set forth in claim 35 wherein the step of moving the backing support includes moving the backing support through the slot from a location below the table surface. 